Dock Leveler Support Frame Height Adjustment
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Solution Overview
Problem
Existing dock leveler support structures require time-consuming shim installation to stabilize and level the dock leveler, which can lead to structural failure or instability due to improper shimming or shim displacement during use.
Innovation Solution
A height-adjustable support frame with a leg assembly and drive mechanism that allows for leveling and stabilization of the dock leveler without shimming, enabling secure attachment to the dock floor without accessing the underside during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If shims are used to stabilize and level the dock leveler support structure, then the dock leveler can be adapted to uneven pit floors, but the installation becomes time-consuming and complex
Solution Approach 1:
The support structure incorporates adjustable legs with threaded rods that can be dynamically adjusted in length during installation. This allows the structure to adapt to uneven pit floors without requiring multiple shims of different thicknesses, significantly reducing installation time while maintaining adaptability.
Solution Approach 2:
The leg length parameter can be changed during installation by rotating the threaded rods to extend or retract the legs. This parameter adjustment allows the support structure to accommodate varying pit floor elevations and slopes, eliminating the need for time-consuming shim selection and installation.
2Stability of the object's composition
If shims are used to level the dock leveler support structure, then the frame can be stabilized on uneven surfaces, but structural failure may occur due to improper shimming or shim displacement
Solution Approach 1:
The adjustable legs provide continuous structural support through their extended length, creating a stable triangular configuration with the frame. This dynamic adjustment capability ensures proper support geometry is achieved, eliminating the risk of shim displacement or inadequate support that could lead to structural failure.
Solution Approach 2:
The threaded rod mechanism allows the installer to self-adjust the leg length to achieve proper support without requiring precise shim thickness selection. The structure serves itself by providing inherent adjustability, ensuring reliable support is achieved through direct observation and adjustment rather than relying on pre-cut shims.
3Stability of the object's composition
If shims are welded in place to stabilize the dock leveler, then the support structure is secured, but access to the underside is required during installation
Solution Approach 1:
The adjustable legs are designed to be modified and secured from the accessible upper side of the frame. The installer can rotate the threaded rods and tighten locking mechanisms without crawling underneath the structure, making the stabilization process as easy as standard assembly operations.
Solution Approach 2:
Instead of requiring access to the underside to install shims and weld them in place, the adjustment mechanism is inverted to the accessible upper side. The threaded rods extend upward from the legs, allowing all adjustment and securing operations to be performed from above, completely eliminating the need for underside access.
4Manufacturing precision
If multiple shims are laminated to shore up the support structure, then the dock leveler can be raised to the correct height, but the installation becomes difficult and time-consuming
Solution Approach 1:
The threaded rod mechanism provides continuous, incremental adjustment capability, allowing precise height control without requiring multiple discrete shim layers. The installer can make fine adjustments by small rotations of the rod, achieving precise leveling in a single operation rather than through complex lamination of multiple shims.
Solution Approach 2:
The leg length parameter can be continuously changed by rotating the threaded rod, providing infinite adjustment resolution within the rod's travel range. This eliminates the need to select and combine specific shim thicknesses to achieve the required height, simplifying the process while maintaining manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The support frame provides stable and level support for dock levelers, eliminating the need for shimming and reducing the risk of structural failure or instability, ensuring safe and reliable operation.
Implementation Method 1
The bell crank includes a first arm extending from a fulcrum to a second end, and a second arm extending from the fulcrum to a third end. Rotating the drive member causes the bell crank to pivot, thereby increasing or decreasing the distance between the foot and the upper frame member.
Data Source
AI summary
A dock leveler support frame includes an upper frame member and a substantially vertical frame member connected thereto. The substantially vertical frame member includes both a structural member and a height-adjusting leg assembly. The leg assembly is adjustable via a drive member proximate the upper frame member. Rotating the drive member raises or lowers the upper frame member by altering the distance between the upper frame member and a foot at the lower end of the leg assembly. Ramp attachment points are also provided proximate the upper frame member. The support frame is installed by placing it in a pit with the upper frame member adjacent the curb, and adjusting the leg assembly to level the upper frame member to the curb. Once level, the back frame is secured to the dock, and the drive member may be secured to the upper frame member to prevent counter-rotation.